Modern vehicles have evolved into true connectivity hubs. Traditional metal whip antennas have been replaced by complex electronic systems integrated into the bodywork, combining multiple functions: radio, GPS, Wi-Fi broadcast and other frequencies. This evolution requires high-precision, high-electrical-conductivity metal components, manufactured in large volumes under strong cost pressure.
In this case study, we follow the challenge faced by a multinational automotive company seeking to optimise the cost of two critical parts for its multimedia antenna system—without compromising performance. ETMA not only identified the ideal raw-material solution but also led the development of technical packaging that transformed the client’s assembly logistics.
CONTEXT: THE RAW-MATERIAL CHALLENGE
The project began with the prototyping of two metal parts, essential to the radio-frequency circuit of the antenna system. Initially, the client specified the use of nickel silver (a special brass alloy composed of copper, nickel and zinc), known for its excellent electrical conductivity and mechanical strength.
Despite its unquestionable performance, the high cost of this material became a barrier to series production—particularly considering the forecast annual volume of 2 million parts per variant.
Technical challenge summary:
- Requirement: maintain high electrical conductivity and the defined geometry;
- Issue: the initial raw material cost (nickel silver) was unsustainable for mass production;
- Goal: identify an alternative material that would meet functional requirements at a significantly lower cost.
THE ETMA SOLUTION: RAW-MATERIAL AND PROCESS INNOVATION
Faced with the challenge, ETMA took on a co-engineering role, actively researching alternative materials.
- First attempt: a tin-plated sheet was tested, but electrical performance did not meet the client’s required standards and was quickly discarded.
- Final solution: ETMA’s technical team identified and validated a pre-nickel-plated strip. Although sourcing was challenging and required a customised supply route (slit-to-width), this material maintained the required level of electrical conductivity and mechanical strength, while delivering a drastic reduction in the total part cost.
The geometry—stabilised and defined during prototyping—was maintained. The industrialisation process, including in-house tool manufacture, ensured that series production would be carried out through stamping on Bihler equipment, a technology that delivers the precision and cycle rate required for annual volumes in the millions.
THE ADDED VALUE: CONDUCTIVE TECHNICAL PACKAGING (ESD)
The truly differentiating element of this project was not limited to the part itself, but rather its packaging. As sensitive electronic components, the risk of electrostatic build-up during transport and handling could compromise final performance. A conductive (ESD-protective) packaging solution was therefore required to address the identified risk.
ETMA led the development of a conductive thermoformed blister, in partnership with a specialised supplier.
Packaging solution benefits:
- ESD protection: the blister plastic incorporates conductive particles, enabling electrons to flow freely and preventing electrostatic charge build-up that could damage the parts.
- Optimised logistics: the tray was designed with specific dimensions, quantity and orientation so the client’s robots can feed directly from the packaging. This removes intermediate handling steps and ensures the parts arrive at the assembly line in optimal condition (ready-to-assemble).
- Integrated service: parts leave ETMA already packed in their final packaging, eliminating the need for the client to outsource this step.
This development demonstrates ETMA’s proactivity in going beyond its core business (metalworking) to solve client logistics and quality challenges, leveraging know-how and its partner network.
The ability to work with medium and large series of small- to medium-sized parts—combined with the flexibility to find both technical and logistical solutions—positions ETMA as a strategic partner, not just a supplier.
CONCLUSION
Replacing the original raw material with a more cost-effective solution, together with innovation in ESD packaging, enabled the automotive client to achieve its cost targets without sacrificing the critical performance of its multimedia antennas. This project highlights ETMA’s key added value: proactive co-engineering and the ability to deliver turnkey solutions—from high-precision metal parts to optimisation of the client’s assembly line.
This capability is supported by a robust industrial model—ETMA’s exclusive system of 10 integrated production processes—which enables technologies to be selected and combined efficiently for each challenge.
Do you have a technical or logistics challenge that requires the right combination of precision, volume and innovation?
Talk to us. We turn demanding requirements into robust industrial solutions—ready to scale.